CN107425230B - Efficiently cooled battery assembly - Google Patents

Efficiently cooled battery assembly Download PDF

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Publication number
CN107425230B
CN107425230B CN201710280412.9A CN201710280412A CN107425230B CN 107425230 B CN107425230 B CN 107425230B CN 201710280412 A CN201710280412 A CN 201710280412A CN 107425230 B CN107425230 B CN 107425230B
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Prior art keywords
battery cell
battery
cooling device
assembly
wall
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CN201710280412.9A
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CN107425230A (en
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艾伦·约瑟夫·吉尔伯特
克里斯汀·S·塔姆
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Ford Global Technologies LLC
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Ford Global Technologies LLC
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00Secondary cells; Manufacture thereof
    • H01M10/60Heating or cooling; Temperature control
    • H01M10/61Types of temperature control
    • H01M10/613Cooling or keeping cold
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00Arrangement or mounting of electrical propulsion units
    • B60K1/04Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K11/00Arrangement in connection with cooling of propulsion units
    • B60K11/02Arrangement in connection with cooling of propulsion units with liquid cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K11/00Arrangement in connection with cooling of propulsion units
    • B60K11/06Arrangement in connection with cooling of propulsion units with air cooling
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    • B60K6/00Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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    • B60K6/00Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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    • B60K6/365Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the transmission gearings with the gears having orbital motion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/22Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
    • B60K6/40Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the assembly or relative disposition of components
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/42Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
    • B60K6/44Series-parallel type
    • B60K6/445Differential gearing distribution type
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10S903/00Hybrid electric vehicles, HEVS
    • Y10S903/902Prime movers comprising electrical and internal combustion motors
    • Y10S903/903Prime movers comprising electrical and internal combustion motors having energy storing means, e.g. battery, capacitor
    • Y10S903/904Component specially adapted for hev
    • Y10S903/907Electricity storage, e.g. battery, capacitor
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S903/00Hybrid electric vehicles, HEVS
    • Y10S903/902Prime movers comprising electrical and internal combustion motors
    • Y10S903/903Prime movers comprising electrical and internal combustion motors having energy storing means, e.g. battery, capacitor
    • Y10S903/904Component specially adapted for hev
    • Y10S903/909Gearing
    • Y10S903/91Orbital, e.g. planetary gears
    • Y10S903/911Orbital, e.g. planetary gears with two or more gear sets
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S903/00Hybrid electric vehicles, HEVS
    • Y10S903/902Prime movers comprising electrical and internal combustion motors
    • Y10S903/903Prime movers comprising electrical and internal combustion motors having energy storing means, e.g. battery, capacitor
    • Y10S903/951Assembly or relative location of components

Abstract

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a battery cell, a cooling device extending at least partially through the battery cell, and a coolant manifold connected to the cooling device.

Description

Efficiently cooled battery assembly
Technical Field
The invention relates to a battery assembly of an electric vehicle battery pack.
Background
The desirability of reducing fuel consumption and emissions from motor vehicles is well documented. Accordingly, vehicles are being developed that reduce or eliminate the dependency on the internal combustion engine altogether. An electric vehicle is one type that is currently being developed for this purpose. Generally, electric vehicles differ from conventional motor vehicles in that they are selectively driven by one or more battery-powered electric motors. In contrast, conventional motor vehicles rely solely on an internal combustion engine to drive the vehicle.
High voltage battery packs typically power the electric motors and other electrical loads of an electric vehicle. The battery pack includes a plurality of battery cells that must be periodically recharged to replenish the energy required to power these loads. The battery cells generate heat, for example, during charge and discharge operations. A relatively complex thermal cooling system is typically employed to manage the heat generated by the battery cells.
Disclosure of Invention
A battery assembly according to an exemplary aspect of the present disclosure includes a battery cell, a cooling device extending at least partially through the battery cell, and a coolant manifold connected to the cooling device.
In another non-limiting embodiment of the above battery assembly, the cooling device is a solid metal rod.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device is a hollow metal tube.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device is a metal platen.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device extends through a void of the battery cell.
In another non-limiting embodiment of any of the foregoing battery assemblies, the battery cell includes an inner wall and an outer wall, and the inner wall bounds the void.
In another non-limiting embodiment of any of the foregoing battery assemblies, the coolant manifold includes an inlet on a first side of the cooling device and an outlet on a second side of the cooling device.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device includes a threaded end that is received within a threaded opening of the coolant manifold.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device is housed within a fitting that is mounted to the coolant manifold. The cooling device and the fitting are connected using an interference fit.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device extends through the battery cell and a second battery cell stacked with the battery cell.
In another non-limiting embodiment of any of the foregoing battery assemblies, the battery cell is a cylindrical battery.
In another non-limiting embodiment of any of the foregoing battery assemblies, the battery cell is a prismatic battery.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device includes a plate, a first mandrel coupled to a first side of the plate, and a second mandrel coupled to a second side of the plate.
In another non-limiting embodiment of any of the foregoing battery assemblies, the first mandrel and the second mandrel extend from a first location inside the battery cell to a second location outside the battery cell. In the second position, the first and second mandrels contact a coolant manifold or Thermal Interface Material (TIM).
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device includes a plate disposed inside the battery cell and a Thermal Interface Material (TIM) extension attached to the plate and extending outside the battery cell.
A battery assembly according to another exemplary aspect of the present disclosure includes a battery cell including a case assembly having an inner wall and an outer wall, an electrode assembly received between the inner wall and the outer wall, and a cooling device extending through a void of the case assembly. The void is defined by an inner wall.
In another non-limiting embodiment of the above battery assembly, the battery cell is a cylindrical battery cell and the cooling device is a solid rod or a hollow tube.
In another non-limiting embodiment of the above battery assembly, the battery cell is a prismatic battery cell and the cooling device is a metal platen.
In another non-limiting embodiment of any of the foregoing battery assemblies, the cooling device extends through a second void formed through the second battery cell.
In another non-limiting embodiment of any of the above battery assemblies, the second battery cell is positioned on the cooling device adjacent to the battery cell such that the positive terminal of the second battery cell contacts the negative terminal of the battery cell.
The embodiments, examples and alternatives of the above paragraphs, the claims or the following description and drawings, including any of their various aspects or features, may be implemented independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless the features are incompatible.
The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
Drawings
FIG. 1 schematically illustrates a powertrain system of an electric vehicle;
FIGS. 2A and 2B illustrate a battery assembly for an electric vehicle battery pack;
FIGS. 2C and 2D illustrate exemplary connections between a cooling device and a coolant manifold of the battery assembly of FIGS. 2A and 2B;
FIG. 3 is a cross-sectional view taken through section A-A of FIG. 2B;
FIG. 4 shows a battery assembly according to a second embodiment of the present disclosure;
fig. 5A and 5B illustrate a battery assembly according to a third embodiment of the present disclosure;
FIG. 6 is a cross-sectional view taken through section B-B of FIG. 5A;
fig. 7 shows a battery assembly according to a fourth embodiment of the present disclosure;
fig. 8A and 8B illustrate a battery assembly according to another embodiment of the present disclosure;
fig. 9A and 9B illustrate a battery assembly according to another embodiment of the present disclosure;
fig. 10A and 10B illustrate a battery assembly according to another embodiment of the present disclosure.
Detailed Description
The present disclosure describes various embodiments of a battery assembly for an electric vehicle battery pack. A battery assembly includes one or more battery cells (e.g., cylindrical, prismatic, or pouch-shaped battery cells) and a cooling device extending at least partially through the battery cells. The cooling device is configured to cool the battery cell conductively or convectively. In some embodiments, the cooling device is a solid bar, a hollow tube, a platen (slab), or some combination of these components. In other embodiments, the cooling device is connected to a coolant manifold configured to deliver a coolant for convectively cooling the battery cells of the battery assembly. These and other components are discussed in more detail in the following paragraphs of this detailed description.
Fig. 1 schematically illustrates a powertrain 10 for an electric vehicle 12. Although described as a Hybrid Electric Vehicle (HEV), it should be understood that the concepts described herein are not limited to HEVs and may be extended to other electric vehicles, including, but not limited to, plug-in hybrid electric vehicles (PHEVs), Battery Electric Vehicles (BEVs), and fuel cell vehicles.
In a non-limiting embodiment, the powertrain 10 is a powertrain that employs a power distribution of a first drive system and a second drive system. The first drive system includes a combination of the engine 14 and the generator 18 (i.e., a first electric machine). The second drive system includes at least a motor 22 (i.e., a second electric machine), a generator 18, and a battery pack 24. In this example, the secondary drive system is considered to be the electric drive system of the powertrain 10. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 28 of the electric vehicle 12. Although a power distribution configuration is depicted in fig. 1, the present invention extends to any hybrid or electric vehicle including a full hybrid vehicle, a parallel hybrid, a series hybrid, a mild hybrid or a micro-hybrid.
The engine 14, which in one embodiment is an internal combustion engine, and the generator 18 may be connected by a power transfer unit 30, such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, may be used to connect the engine 14 to the generator 18. In one non-limiting embodiment, power-transfer unit 30 is a planetary gear set that includes a ring gear 32, a sun gear 34, and a planet carrier assembly member 36.
The generator 18 may be driven by the engine 14 through a power transfer unit 30 to convert kinetic energy into electrical energy. The generator 18 may additionally function as a motor to convert electrical energy to kinetic energy to output torque to a shaft 38 connected to the power transfer unit 30. Because the generator 18 is operatively connected to the engine 14, the rotational speed of the engine 14 may be controlled by the generator 18.
The ring gear 32 of the power transfer unit 30 may be connected to a shaft 40, the shaft 40 being connected to the vehicle drive wheels 28 via a second power transfer unit 44. Second power transfer unit 44 may include a gear set having a plurality of gears 46. Other power transfer units may also be suitable. Gear 46 transfers torque from the engine 14 to a differential 48 to ultimately provide tractive effort to the vehicle drive wheels 28. Differential 48 may include a plurality of gears configured to transmit torque to vehicle drive wheels 28. In one embodiment, second power transfer unit 44 is mechanically coupled to an axle 50 through a differential 48 to distribute torque to vehicle drive wheels 28.
The motor 22 may also be used to drive the vehicle drive wheels 28 by outputting torque to a shaft 52 that is also connected to the second power transfer unit 44. In one embodiment, the motor 22 and the generator 18 cooperate as part of a regenerative braking system in which the motor 22 and the generator 18 may act as motors to output torque. For example, the motor 22 and the generator 18 may each output electrical power to the battery pack 24.
The battery pack 24 is an exemplary electric vehicle battery. The battery pack 24 may be a high-voltage traction battery pack that includes a plurality of battery assemblies 25 (i.e., an array or stack of battery cells) that are capable of outputting electrical power to operate the motor 22, the generator 18, and/or other electrical loads of the electric vehicle 12. Other types of energy storage devices and/or output devices may also be used to electrically power the electric vehicle 12.
In one non-limiting embodiment, the electric vehicle 12 has two basic modes of operation. The electric vehicle 12 may operate in an Electric Vehicle (EV) mode, wherein the motor 22 (typically not assisted by the engine 14) is used for vehicle propulsion, consuming the state of charge of the battery pack 24 up to its maximum allowable discharge rate under certain driving modes/cycles. The EV mode is an example of a charge-consuming operation mode of the electric vehicle 12. During the EV mode, the state of charge of the battery pack 24 may increase under certain conditions, for example, due to regenerative braking over a period of time. The engine 14 is normally OFF (OFF) in the default EV mode, but the engine 14 may be operated according to vehicle system conditions or as the operator allows.
The electric vehicle 12 may additionally operate in a Hybrid Electric (HEV) mode, in which both the engine 14 and the motor 22 are used for vehicle propulsion. The HEV mode is an example of a charge sustaining mode of operation of the electric vehicle 12. During the HEV mode, the electric vehicle 12 may reduce the propulsive effort of the motor 22 in order to maintain the state of charge of the battery pack 24 at a constant or near constant level by increasing the propulsion of the engine 14. In addition to EV and HEV modes within the scope of the present disclosure, the electric vehicle 12 may be operated in other operating modes.
Fig. 2A and 2B illustrate an exemplary battery assembly 25 that may be used in an electric vehicle battery pack, such as the battery pack 24 of the electric vehicle 12 of fig. 1. The battery assembly 25 includes a plurality of battery cells 56 for providing power to various electrical loads of the electric vehicle 12. Although two battery cells 56 are shown in fig. 2A and 2B, the battery assembly 25 may use a greater or lesser number of battery cells within the scope of the present disclosure. In other words, the present disclosure is not limited to the specific configuration shown in fig. 2A and 2B. The cells 56 may be stacked relative to one another along the longitudinal axis a to form a group of cells 56, sometimes referred to as a "cell stack.
In a first non-limiting embodiment, the battery cells 56 are cylindrical lithium ion batteries. However, the present disclosure is not limited to cylindrical batteries and may extend to batteries having other geometries (prismatic, pouch, etc.) or other chemical compositions (nickel-metal hydride, lead acid, etc.). An exemplary embodiment showing a prismatic battery cell is shown in fig. 5A, 5B, 6, 8A, 8B, 9A, 9B, 10A, and 10B, and an exemplary embodiment showing a pouch-shaped battery cell is shown in fig. 7.
In some cases, the battery cell 56 generates heat. It is desirable to manage this heat to improve the capacity and life of the battery cells 56, thereby increasing the efficiency of the battery pack 24. The various components for actively managing this heat are therefore described in detail in the embodiments described below.
The battery assembly 25 of fig. 2A and 2B includes a cooling device 58 disposed through a void 60 formed in the battery cell 56. The battery unit 56 may be slid onto the cooling device 58. The battery cell 56 and the cooling device 58 may engage one another with an interference fit. In a non-limiting embodiment, the cooling device 58 extends completely through each battery cell 56 of the battery assembly 25. In other words, the void 60 extends all the way through the battery cell 56.
Each battery cell 56 includes a positive terminal (represented by the symbol (+) and a negative terminal (represented by the symbol (-)). In another non-limiting embodiment, the battery cells 56 are stacked on top of each other on the cooling device 58 such that each negative terminal is positioned adjacent to and contacts a positive terminal of an adjacent battery cell 56. Therefore, in the present embodiment, the bus bars are not required to electrically connect the battery cells 56.
In a first non-limiting embodiment, the cooling device 58 is a solid bar made of a metallic material (see FIG. 2A). The cooling device 58 may be covered with a thermal interface material that provides high thermal conductivity but high electrical isolation. In another non-limiting embodiment, the cooling device 58 itself is made of a TIM. In such embodiments, heat generated by the battery cells 56 is conducted from the battery cells 56 to the cooling device 58. And then releases heat to a coolant C (e.g., air, water mixed with glycol or some other fluid) passing within a coolant manifold 62 connected to the cooling device 58. The coolant C conducts heat away from the battery assembly 25. In an alternative embodiment, the coolant manifold 62 is a solid device that acts as a cooling plate to dissipate heat.
In a second non-limiting embodiment, the cooling device 58 is a hollow tube made of a metallic material (see FIG. 2B). In use, heat generated by the battery cells 56 is convectively transferred from the battery cells 56 to the coolant C passing through the channels 64, the channels 64 being formed by the cooling device 58. The coolant C conducts heat away from the battery assembly 25. The coolant C enters the channels 64 from the inlet 66 of the coolant manifold 62 and exits the channels 64 into the outlet 68 of the coolant manifold 62. In other words, the passage 64 is fluidly connected to an inlet 66 and an outlet 68 that may be disposed at opposite ends of the cooling device 58 in a non-limiting embodiment. The coolant manifold 62, including an inlet 66 and an outlet 68, is part of a closed loop system for passing the coolant C through the cell assembly 25. Although not shown, the closed-loop system may additionally include a coolant reservoir and a coolant pump.
The cooling device 58 may be fluidly connected to a coolant manifold 62 of the battery assembly 25 to provide a sealed connection between these components. The battery cells 56 are removed from fig. 2C and 2D to better illustrate the connection between the cooling device 58 and the coolant manifold 62. In a first non-limiting embodiment shown in FIG. 2C, the cooling device 58 includes a threaded end 70 that is inserted into a threaded opening 72 formed in the coolant manifold 62. In a second non-limiting embodiment shown in FIG. 2D, the cooling device 58 is received within a fitting (fitting)74 mounted to the coolant manifold 62. The cooling device 58 and the fitting 74 may be sized to engage one another using an interference fit. Other connections between the cooling device 58 and the coolant manifold 62 are also within the scope of the present disclosure.
Referring now to the cross-sectional view of fig. 3, each cell 56 includes a can assembly 76 and an electrode assembly 78 housed inside the can assembly 76. The shell assembly 76 may include an inner wall 80, an outer wall 82 generally defining the inner wall 80, and a space 84 extending between the inner wall 80 and the outer wall 82 to receive the electrode assembly 78. In this embodiment, the inner wall 80 and the outer wall 82 are cylindrical members. An electrode assembly 78, sometimes referred to as a jelly roll, is wound around the inner wall 80. The cooling device 58 passes through the void 60 of each battery cell 56. The void 60 is positioned through the center of the inner wall 80, and thus, once the cooling device 58 is received through the battery cell 56, the inner wall 80 defines the void 60 and the cooling device 58 separates the electrode assembly 78 from the cooling device 58.
Fig. 4 shows another exemplary battery assembly 25A. In this non-limiting embodiment, battery assembly 25A includes a plurality of battery cell stacks 99, each battery cell stack 99 including a cooling device 58A received through a plurality of battery cells 56A. Each cell stack 99 is mounted to the coolant manifold 62A. This embodiment illustrates the scalable nature of the battery assembly of the present disclosure. The battery assembly disclosed herein may be modified to include any number of battery cells and any number of cooling devices for achieving a desired energy density and level of cooling within the battery pack 24.
Fig. 5A and 5B show another battery assembly 25B. Battery assembly 25B includes a plurality of battery cells 56B and a cooling device 58B extending through each of the plurality of battery cells 56B. In this non-limiting embodiment, battery cell 56B is a prismatic lithium ion battery.
Each battery cell 56B includes a positive terminal (designated by the symbol (+) and a negative terminal (designated by the symbol (-)). In a non-limiting embodiment, the battery cells 56B are stacked alongside one another on the cooling device 58 such that each negative terminal is positioned adjacent to and in contact with a positive terminal of an adjacent battery cell 56B. Thus, in this non-limiting embodiment, the bus bars need not electrically connect the battery cells 56.
In another non-limiting embodiment, the cooling device 58B is a metal platen or plate that is received through the battery cell 56B. The cooling device 58B may be a solid metal platen for conductively cooling the battery cell 56B, or may be a hollow metal platen for convectively cooling the battery cell 56B.
Referring now to the cross-sectional view of fig. 6, each battery cell 56B includes a case assembly 76B and an electrode assembly 78B housed within case assembly 76B. The shell assembly 76B may include an inner wall 80B, an outer wall 82B generally defining the inner wall 80B, and a space 84B extending between the inner wall 80B and the outer wall 82B for receiving the electrode assembly 78B. In this embodiment, the inner wall 80B and the outer wall 82B are rectangular members. The electrode assembly 78B is wound around the inner wall 80B. The cooling device 58B passes through the void 60B of each battery cell 56B. Void 60B is positioned through the center of inner wall 80B, such that once cooling device 58B is received through battery cell 56B, inner wall 80B defines void 60B and cooling device 58B, and separates electrode assembly 78B from cooling device 58B.
Fig. 7 illustrates another exemplary battery assembly 25C. Battery assembly 25C includes a battery cell 56C and a cooling device 58C extending at least partially through battery cell 56C. In this non-limiting embodiment, the battery cell 56C is a pouch battery cell. Battery cell 56C includes a case assembly 76C and an electrode assembly 78C housed within case assembly 76C. In a further non-limiting embodiment, once cooling device 58C is received within battery cell 56C, electrode assembly 78C is wound around cooling device 58C. Although not shown, an insulating layer may be located between the electrode assembly 78C and the cooling device 58C to electrically isolate these components from each other.
Another exemplary battery assembly 25D is shown in fig. 8A and 8B. Battery assembly 25D includes a plurality of battery cells 56D, which in this embodiment are configured as prismatic battery cells, and a plurality of associated cooling devices 58D. In the present embodiment, each battery cell 56D includes its own cooling device 58D. Further, unlike the previous embodiment, the cooling device 58D of the battery assembly 25D extends only partially through the battery cell 56D.
The battery cells 56D are stacked side-by-side along the longitudinal axis a to form a battery assembly 25D (see, e.g., fig. 8B). Each cell 56D includes a positive terminal 90D and a negative terminal 92D. In a non-limiting embodiment, the battery cells 56D are stacked side-by-side along the longitudinal axis a such that the negative terminal 92 is positioned adjacent to and in contact with the positive terminal 90 of an adjacent battery cell 56D. In another non-limiting embodiment, a Thermal Interface Material (TIM)94D is positioned between adjacent battery cells 56D of battery assembly 25D.
Each battery cell 56D includes a case assembly 76D and an electrode assembly 78D housed inside the case assembly 76D. The electrode assembly 78B may be wound around the cooling device 58D (best shown in fig. 8B).
Each cooling device 58D may include a plate 86D and a mandrel 88D connected to the plate 86D, for example, at an opposite end of the plate 86D. In a non-limiting embodiment, electrode assembly 78D of battery cell 56D is wrapped around cooling device 58D within casing assembly 76D. In this embodiment, mandrel 88D, which is a hollow tube, extends from a first position inside shell assembly 76D to a second position outside shell assembly 76D. In the second position, one of the mandrels 88D is connected to the manifold inlet 66D and the other mandrel 88D is connected to the manifold outlet 68D (see fig. 8A).
Together, the plate 86D and the mandrel 88D establish a serpentine cooling channel 96D for directing the coolant C through the cooling device 58D to convectively cool the battery cell 56D. For example, in use, coolant C is directed from the manifold inlet 66D to the first of the mandrels 88D (left hand side of fig. 8A). The coolant C is then directed through the serpentine cooling channel 96D and then exits from the second one of the mandrels 88D (the right hand side of fig. 8A) into the manifold outlet 68D. As the coolant C circulates along the path established by the serpentine cooling channel 96D, heat from the battery cell 56D is released into the coolant C.
Fig. 9A and 9B illustrate another exemplary battery assembly 25E for an electric vehicle battery pack. Similar to battery assembly 25D described above, battery assembly 25E includes a cooling device 58E having a plate 86E and a spindle 88E for thermally managing heat rejected by battery cells 56E. However, in the present embodiment, the cooling device 58E does not convectively cool the battery cell 56E but conductively cools the battery cell 56E. Mandrel 88E, which in this embodiment is a solid rod, extends outside of shell assembly 76E of cell 56E and may contact Thermal Interface Material (TIM) 98. The TIM 98E may be in contact with another structure, such as a cooling plate or other heat sink.
Another exemplary battery assembly 25F is shown in fig. 10A and 10B. The battery assembly 25F includes a cooling device 58F for cooling the battery cell 56F. The cooling device 58F extends at least partially through the battery cell 56F.
In a non-limiting embodiment, the cooling device 58F includes a plate 86F and a mandrel 88F connected near opposite ends of the plate 86F. Electrode assembly 78F of cell 56F is wound around cooling device 58F within case assembly 76F of cell 56F (see fig. 10B). In another non-limiting embodiment, the cooling device 58F includes a TIM extension 95F connected to the plate 86F. The TIM extension 95F protrudes from the plate 86F to a position outside of the casing assembly 76F and may contact a cooling plate or other heat sink (not shown).
While different non-limiting embodiments are shown with specific components or steps, embodiments of the disclosure are not limited to those specific combinations. Some features or characteristics of any non-limiting embodiment may be used in combination with features or characteristics from any other non-limiting embodiment.
It should be understood that the same reference numerals indicate corresponding or similar elements throughout the several views. It should be understood that although a particular component arrangement is disclosed and shown in these exemplary embodiments, other arrangements may benefit from the teachings of the present disclosure.
The above description should be construed as illustrative and not in any restrictive sense. One of ordinary skill in the art would understand that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the true scope and content of this disclosure.

Claims (11)

1. A battery assembly, comprising:
a battery cell;
a second battery cell;
the battery cell and a second battery cell each comprising a positive terminal at a first surface and a negative terminal at a second surface disposed opposite the first surface, the second battery cell stacked on the battery cell such that the negative terminal of the second battery cell is adjacent the positive terminal of the battery cell;
a cooling device extending at least partially through the battery cell and the second battery cell; and
a coolant manifold connected to the cooling device.
2. The battery assembly of claim 1, wherein the cooling device is a solid metal rod, a hollow metal tube, or a metal platen.
3. The battery assembly of claim 1 or 2, wherein the cooling device extends through a void of the battery cell.
4. The battery assembly of claim 3, wherein the battery cell comprises an inner wall and an outer wall, and the inner wall defines the void.
5. The battery assembly of claim 1, wherein the coolant manifold comprises an inlet on a first side of the cooling device and an outlet on a second side of the cooling device.
6. The battery assembly of claim 1, wherein the cooling device comprises a threaded end received within a threaded opening of the coolant manifold.
7. The battery assembly of any of the preceding claims, wherein the cooling device is received within a fitting mounted to the coolant manifold, the cooling device and the fitting connected using an interference fit.
8. The battery assembly of claim 1 or 2, wherein the cooling device comprises a plate, a first mandrel connected to a first side of the plate, and a second mandrel connected to a second side of the plate, wherein the first and second mandrels extend from a first location within the battery cell to a second location outside the battery cell where the first and second mandrels contact the coolant manifold or Thermal Interface Material (TIM).
9. The battery assembly of claim 1 or 2, wherein the cooling device comprises a plate disposed within the battery cell and a Thermal Interface Material (TIM) extension attached to the plate and extending outside of the battery cell.
10. The battery assembly of claim 1, wherein the battery cell comprises a housing component having an inner wall and an outer wall and an electrode assembly received between the inner wall and the outer wall, and wherein the cooling device extends through a void of the housing component, the void defined by the inner wall.
11. A battery assembly, comprising:
a battery cell and a second battery cell, the battery cell and the second battery cell each comprising a housing assembly having an inner wall and an outer wall, the battery cell and the second battery cell each comprising a positive terminal at a first surface and a negative terminal at a second surface disposed opposite the first surface, the second battery cell stacked on the battery cell such that the negative terminal of the second battery cell is adjacent the positive terminal of the battery cell;
an electrode assembly housed between the inner wall and the outer wall; and
a cooling device extending through a void of the shell assembly, the void defined by the inner wall.
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